UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C. 20555
July 6, 1989
Information Notice No. 89-45, SUPPLEMENT 1: METALCLAD, LOW-VOLTAGE POWER
CIRCUIT BREAKERS REFURBISHED
WITH SUBSTANDARD PARTS
Addressees:
All holders of operating licenses or construction permits for nuclear power
reactors.
Purpose:
This information notice supplement is being provided to present additional
information regarding the supply of surplus or refurbished circuit breakers
and related electrical equipment to nuclear power plants as discussed in NRC
Information Notice No. 89-45. It is expected that recipients will review this
information for applicability to their facilities and consider actions, as
appropriate, to avoid similar problems. However, suggestions contained in
this information notice do not constitute NRC requirements; therefore, no
specific action or written response is required.
Description of Circumstances:
Information Notice No. 89-45 discussed a General Electric (GE) type
AKF-2-25 metalclad, low-voltage power circuit breaker (field discharge configu-
ration) from the Quad Cities nuclear power plant found to be refurbished with
nonstandard and substandard parts.
In conducting followup inspections at utilities that have procured circuit
breakers of this type and other related electrical equipment from Satin Ameri-
can Corporation, the NRC has learned of the existence of other equipment from
Satin American, refurbished with nonstandard and possibly substandard parts
and fabrication methods, some of which may contain latent defects resulting
from the introduction of nonstandard materials and components. These defects
may not be readily detectable by means of normal inspection and testing, and
the nature of the defects is such that they could render the equipment
inoperable without warning.
Discussion:
Recent information, received in the course of the NRC's review and inspections
of refurbished electrical equipment, indicates that GE EC-type, series
overcurrent trip devices (particularly EC-1 and EC-2A) commonly used in GE
8907060183
. IN 89-45, Supplement 1
July 6, 1989
Page 2 of 3
AK-type, low-voltage power circuit breakers, and supplied by a vendor other
than the original manufacturer, may have been represented as new or original
equipment. Documentation such as "certificates of certification" stated that
the trip devices were "duplicates" of "identical" equipment originally sup-
plied, when in fact, they were refurbished. Many were fitted with irregular
nameplates and nonstandard and substandard parts. The trip devices were
supplied primarily during the period 1983 through 1987. These electro-
mechanical devices are presently used in Class 1E DC electrical systems
because the newer solid-state devices use current trans-formers as sensors
which do not operate on DC. They are also used in safety-related AC
electrical systems that may be exposed to the harsh radiation environments of
design-basis accidents. Solid-state trip devices have limited capability to
withstand the effects of accident radiation doses greater than 10,000 rads or
to function properly under the conditions of high accident radiation dose
rates.
Of particular concern is the fact that, in addition to irregular nameplates
and refurbishments not in accordance with the manufacturer's specifications,
some of the units could be considered potentially defective as a result of the
use of nonstandard parts and questionable refurbishing methods. Specifically,
disassembly and detailed examination of trip units supplied to Nine Mile
Point, Unit 1, by Satin American revealed that some trip units were modified,
apparently to alter their trip characteristics, by (1) substituting series
coils with nonstandard numbers of turns, (2) changing instantaneous trip
springs and/or varying the number of active spring turns and/or adjusting
tension to compensate, and (3) altering longtime trip characteristics by such
practices as using nonstandard longtime trip calibration springs, apparently
enlarging the bleed orifices in the dashpot pistons and/or substituting
pistons (the markings of some of which were found to be incorrect for the
nameplate longtime trip characteristic and current rating) or using other than
the original dashpots to obtain different time delays. Additionally, in some
trip units examined, the samples of oil taken from the dashpots exhibited some
variance from their expected color and odor, indicating that the mechanical
modifications may have been complemented by the use of nonstandard dashpot
oils (of yet undetermined composition, viscosity, and compatibility) to aid in
obtaining the desired longtime trip characteristics.
Aside from the issue of representation of refurbished equipment as original,
such modifications constitute the introduction of potential latent defects
into equipment, already of indeterminate quality, that would not be readily
detected by normal field testing and inspection and which could result in
degraded trip unit performance, inability to be adjusted properly, or failure
to operate entirely.
Attachment 1 identifies differences that have been observed between several
characteristics of construction of refurbished series overcurrent trip devices
as supplied by Satin American and original ones from GE. Some of these at-
tributes, identified by an asterisk (*), can often be observed without
removing an installed trip unit from its circuit breaker (although the breaker
may have to be racked out) and the rest may be observed by removing only the
trip unit cover. These attributes may be used to identify refurbished units,
although they, in themselves, may not all represent defects.
. IN 89-45, Supplement 1
July 6, 1989
Page 3 of 3
Attachment 2 tabulates differences between various attributes of irregular
nameplates found on some refurbished series overcurrent trip devices supplied
by Satin American and authentic ones from GE. These differences may also be
used to identify refurbished units.
Addressees are cautioned that although the differences described in
Attachments 1 and 2 may be used to identify refurbished units from one vendor,
each characteristic should be considered, since not all refurbished units will
exhibit all of the differences that have been identified. Therefore, the lack
of some of the differences described, or variations on them, should not be
considered sufficient evidence to conclude that a given trip unit has not been
refurbished.
The NRC is particularly interested in obtaining information on circuit
breakers and related electrical equipment supplied by Satin American or others
in which differences or deficiencies have been found that are similar to those
described in IN 89-45 and this supplement. Of special interest is information
on recent procurements. Documentation, in as much detail as practicable, of
any such differences or deficiencies discovered, especially in cases in which
a piece of equipment may have been improperly serviced or refurbished, is
important. Licensees may communicate information of this type by telephone to
one of the technical contacts listed below.
No specific action or written response is required by this information notice
supplement. If you have any questions about this matter, please contact one
of the technical contacts listed below or the Regional Administrator of the
appropriate regional office.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical Contacts: S. D. Alexander, NRR
(301) 492-0995
U. Potapovs, NRR
(301) 492-0984
Attachments:
1. Observed Differences in Original and Refurbished Trip Device Construction
2. Observed Differences in Authentic and Irregular Trip Device Nameplates
3. List of Recently Issued NRC Information Notices
. Attachment 1
IN 89-45, Supplement 1
July 6, 1989
Page 1 of 1
OBSERVED DIFFERENCES IN ORIGINAL AND REFURBISHED TRIP DEVICE CONSTRUCTION
This attachment identifies differences that have been observed between several
characteristics of construction of refurbished series overcurrent trip devices
as supplied by Satin American and original ones from GE. Some of these at-
tributes, identified by an asterisk (*), can often be observed without
removing an installed trip unit from its circuit breaker (although the breaker
may have to be racked out) and the rest may be observed by removing only the
trip unit cover. These attributes may be used to identify refurbished units.
COMPONENT ORIGINAL GE REFURBISHED
*1. Magnetic structure Fastened with Fastened with split
pole-piece laminations rivets pins (also called
roll-pins)
*2. EC-2A dashpot fasteners Riveted to frame Bolted to frame with
nuts and machine screws
3. Longtime calibration Half near adjusting Slightly larger
spring (EC-2A) thumbwheel is painted; diameter and not
color corresponds to painted
rating range.
4. EC-2A instantaneous Usually 8 active turns > 9 active turns,
trip adjusting spring and 1 inactive turn, painted including screw
unpainted (1) adjusting nut or < 8
active turns
*5. Paint on magnetic Flat black, even and Glossy, drips, may be
structure and/or frame smooth applied over rust
6. Dashpot lever arm shaft Secured with two wraps May still use old style
rubber oil seal boots of copper wire, ends pinch/spring type
twisted since 1984 "hose" clamps
7. Longtime trip dashpots Cast aluminum alloy Body may have been
body - unfinished sandblasted
*8. Square, flat cardboard Usually bears handwrit- Often shows no marking
series coil insulators ten instantaneous trip or is a used insulator,
setting marking and the inverted so original
tester's rubberstamp marks are hidden
*9. EC-1 trip setting or Factory set for long- Replacement plates
calibration plates time and short-time stamped to work on
characteristics, refurbished unit,
bright aluminum, coarse matte finish, finer
stamped characters stamped characters
*10. Series coil: condition, Uniform amber "varnish" Discolored/darkened;
number of turns, lug insulation, number of may appear recoated,
type, and position turns correct for cur- overheated; may have
rent rating wrong lug pattern or
number of turns
________________
Note 1: Consult technical documentation and/or the manufacturer for specific
functional and construction specifications if in doubt.
. Attachment 2
IN 89-45, Supplement 1
July 6, 1989
Page 1 of 1
OBSERVED DIFFERENCES IN AUTHENTIC AND IRREGULAR TRIP DEVICE NAMEPLATES
This attachment tabulates differences between various attributes of irregular
nameplates found on some refurbished series overcurrent trip devices supplied
by Satin American and authentic ones from GE. These attributes can usually be
observed without removing an installed trip unit from its circuit breaker
(although the breaker may have to be racked out). These differences may be
used in conjunction with Attachment 1 to identify refurbished units.
ATTRIBUTE AUTHENTIC GE IRREGULAR NAMEPLATE
1. Finish on EC-1 Bright brushed aluminum White anodized/matte-
nameplates finished aluminum
2. Finish on EC-2A White anodized finish Similar finish,
nameplates often lacquered but not lacquered
3. "INSPECTED" block Unique, single-line Blank or stamp figure
stamps (made at GE closed figure/shape(1) made by reorienting
Plainville, CT factory (not used on new units and/or superimposing
prior to about 1984) made after 1984 at GE one standard stamped
Atlanta, GA factory) character on another
4. Shop or work order Letters "ATL-" followed Not seen on refur-
number (only on trip by unique five-digit bished trip units
units made in GE Atlan- number usually stamped with irregular
ta factory, 1984 on) in upper left corner(1) nameplates
5. Date code (should not Stamped, 2-ltr code on Present on most EC-2As,
appear on plates with top line between catalog missing on many EC-1s
shop order number)(1) "NO." and type desig- examined, year and
nation, year ltr month letters same
different weight from weight
month letter
6. "NO." block (catalog 0549D0497G-1 printed on May be stamped onto
part or drawing number) EC-2As of this design irregular nameplates
7. "NO." block "NO." corresponds to Numbers may not
type and unique "NP" correspond correctly
(nameplate) number for or be valid at all
each design(1)
8. "NO." block "8"s in "NO." block on Plain figure "8"s
EC-1s appear as: "8 "
e.g., 238D685G-1
9. Frequency symbol "CY" Printed on EC-1s Stamped
10.Stamped characters Darkened with paint Darkened with grease
11.EC-1 trip setting Coarse stamped numbers Finer numbers, gradu-
calibration plates ations closer spaced
12.EC-2A type designation "EC-2A" printed "A" suffix stamped
________________
Note 1: Consult manufacturer for identification of valid date codes, catalog
numbers (and corresponding nameplate numbers), inspection stamps,
and shop order numbers.
. Attachment 3
IN 89-45, Supplement 1
July 6, 1989
Page 1 of 1
LIST OF RECENTLY ISSUED
NRC INFORMATION NOTICES
_____________________________________________________________________________
Information Date of
Notice No._____Subject_______________________Issuance_______Issued to________
89-55 Degradation of Containment 6/30/89 All holders of OLs
Isolation Capability by a or CPs for nuclear
High-Energy Line Break power reactors.
89-54 Potential Overpressurization 6/23/89 All holders of OLs
of the Component Cooling or CPs for nuclear
Water System power reactors.
89-53 Rupture of Extraction 6/13/89 All holders of OLs
Steam Line on High or CPs for nuclear
Pressure Turbine power reactors.
88-46, Licensee Report of 6/8/89 All holders of OLs
Supp. 3 Defective Refurbished or CPs for nuclear
Circuit Breakers power reactors.
89-52 Potential Fire Damper 6/8/89 All holders of OLs
Operational Problems or CPs for nuclear
power reactors.
89-51 Potential Loss of Required 5/31/89 All holders of OLs
Shutdown Margin During or CPs for nuclear
Refueling Operations power reactors.
88-88, Degradation of Westinghouse 5/31/89 All holders of OLs
Supp. 1 ARD Relays or CPs for nuclear
power reactors.
89-50 Inadequate Emergency 5/30/89 All holders of OLs
Diesel Generator Fuel or CPs for nuclear
Supply power reactors.
89-49 Failure to Close Service 5/22/89 All holders of OLs
Water Cross-Connect or CPs for nuclear
Isolation Valves power reactors.
89-48 Design Deficiency in the 5/22/89 All holders of OLs
Turbine-Driven Auxiliary or CPs for nuclear
Feedwater Pump Cooling power reactors.
Water System
_____________________________________________________________________________
OL = Operating License
CP = Construction Permit
..